Panel connector devices

ABSTRACT

A device and method for the protection of a first member and second member from corrosion by utilizing a connector that bonds the members without allowing direct contact of the members.

FIELD OF THE INVENTION

The present teachings are predicated upon methods and devices for theconnection of panel structures including a joint having a channel forreceiving at least a portion of a panel and an adhesive sealant materiallocated within the channel.

BACKGROUND OF THE INVENTION

Truck trailer construction presents a number of challenges related toconnecting side wall panels, repair of side wall panels and corrosion.Generally, adjacent panels are connected with many rivets that make bothconstruction and repair of the panels time consuming and laborintensive.

U.S. Pat. No. 7,993,719 discloses a mass transit vehicle formed ofcomposite panels, releasable adhesive joints. U.S. Pat. No. 7,152,909teaches a trailer body including wall and floor panels including anI-beam post/cross-member defined in an extrusion profile. U.S. Pat. No.6,314,704 teaches a structural building panel including a compositetruss member having transverse truss elements, first and secondcomposite skins, and a composite connector extends along a side edge ofthe panel.

There remains a need for connectors that reduce the need for mechanicalfasteners for connecting trailer side wall panels and also provide forrepair ease and minimized corrosion.

SUMMARY OF THE INVENTION

The present invention meets some or all of the above needs by providinga profile for use in a joint for connecting adjoining structural memberscomprising a central portion that is generally tubular; at least onepair of spaced apart opposing flanges defining a channel; and anadhesive sealant that is present on the profile within the channel in agreen state and which is adapted to be activated by a pre-selectedcondition for bonding to and sealing at least one structural member.

The adhesive sealant may be expandable. The adhesive sealant may beexpanded in place. The adhesive sealant may be heat activated. Theprofile may be adapted for allowing removal and replacement of theadjoining structural members. The profile may be formed of a singlematerial. The profile may be formed of more than one material. Theprofile may be extruded. The profile may be pultruded. The profile mayinclude an aluminum material. The profile may include a steel material.The profile may include a polymeric material. The profile may include aglass-reinforced polymeric material. The profile may be a one-piecemember. The profile may be a two-piece member. The adhesive sealant maybe an epoxy-based material. The adhesive sealant may have a T_(g) thatdiffers from that of any adhesive located on the adjoining structuralmembers so that any de-bonding process de-bonds only the adhesivesealant and not the adhesive on the adjoining structural members. Theadjoining structural members may include a corrugated material. Theadhesive sealant may fill gaps along a terminal edge of the corrugatedmaterial. The adhesive sealant may fill gaps along a terminal edge ofthe adjoining structural members. The profile may be adapted forreceiving substantially planar adjoining structural members. Theadjoining structural members may include opposing skins and anintermediate layer. The shape of the profile may prevent the adhesivesealant from expanding over an edge of the adjoining structural members.The adhesive sealant may be located in between the profile and anyadjoining structural member so there is no direct contact between theprofile and any adjoining structural member.

The present teaching further provide for a panel structure for acontainer, the container including at least two elongated panels and ajoint located between the panels and for securing the panels to oneanother. The joint may have an elongated profile that defines a pair ofchannels into which the panels are placed and in which an activatedadhesive sealant resides between the panels and the profile foradhesively bonding and sealing the panels and the profile to oneanother. The elongated profile in cross section may have a configurationthat includes a central portion that is generally tubular and includesat least one pair of spaced apart opposing flanges defining a channel.

The adhesive sealant utilized in the panel structure may be expandable.The adhesive sealant may be expanded in place. The adhesive sealant maybe heat activated. The joint may be adapted for allowing removal andreplacement of the panels. The elongated profile may be formed of asingle material. The elongated profile may be formed of more than onematerial. The elongated profile may be extruded. The elongated profilemay be pultruded. The elongated profile may include an aluminummaterial. The elongated profile may include a steel material. Theelongated profile may include a polymeric material. The elongatedprofile may include a glass-reinforced thermoplastic material. Theelongated profile may be a one-piece member. The elongated profile maybe a two-piece member. The adhesive sealant may be an epoxy-basedmaterial. The adhesive sealant has a T_(g) that differs from that of anyadhesive located on the panels so that any de-bonding process de-bondsonly the adhesive sealant and not the adhesive on the adjoiningstructural members. The panels may include a corrugated material. Theadhesive sealant may fill gaps along a terminal edge of the corrugatedmaterial. The adhesive sealant may fill gaps along a terminal edge ofthe panels. The elongated profile may be adapted for receivingsubstantially planar panels. The panels may include opposing skins andan intermediate layer. The shape of the profile may prevent the adhesivesealant from expanding over an edge of the panel. The adhesive sealantmay be located in between the profile and any portion of the panel sothere is no direct contact between the profile and any portion of thepanel.

The present teachings also provide for a hollow container comprising apair of spaced apart opposing longitudinal extending upper rails, a pairof spaced apart opposing longitudinal extending lower rails that aregenerally parallel to one another and a plurality of posts extendingbetween respective upper and lower rails and being arranged generallyparallel relative to each other. The hollow container may furtherinclude a plurality of roof bows generally perpendicular to the postsand spanning between the opposing upper rails and generally parallel toone another and a roof supported on the roof bows. A plurality of sidewall panels between successive posts and being connected to the postswith an adhesive sealant that has been activated in place for adhesionand sealing may also be included.

The posts may be adapted for allowing removal and replacement of thepanels. The posts may be formed of a single material. The posts may beformed of more than one material. The posts may be extruded orpultruded. The posts may include an aluminum material. The posts mayinclude a steel material. The posts may include a polymeric material.The posts may include a glass-reinforced thermoplastic material. Theposts may comprise a one-piece member. The posts may comprise atwo-piece member. The panels may include a corrugated material. Theposts may be adapted for receiving substantially planar panels. Theshape of the posts may prevent the adhesive sealant from expanding overan edge of the panel. The adhesive sealant may be located in between theposts and any portion of the panel so there is no direct contact betweenthe posts and any portion of the panel.

The present teaching further provide for a method of making the profilereference herein including co-extruding a pair of spaced apart opposingflanges defining a channel and an adhesive sealant so that the adhesivesealant is present within the channel in a green state and is adapted tobe activated by a pre-selected condition for bonding to and sealing atleast one structural member.

The teachings herein also provide for a method of making the panelstructure described herein comprising forming at least two elongatedpanels, locating a joint between the panels for securing the panels toone another, locating the at least two elongated panels into a pair ofchannels forming the joint and activating an adhesive sealant residingbetween the panels and the profile for adhesively bonding and sealingthe panels and the joint to one another.

The teachings herein also provide for a method of repairing the panelstructure described herein including de-bonding an adhesive sealantlocated in a pair of channels, removing an elongated panel from withinthe pair of channels and replacing the elongated panel with a secondelongated panel or a repaired panel.

The adhesive sealant may be activated after extruding the adhesivesealant within the channel. The de-bonding may occur with theapplication of heat.

The connector system of the present teachings provides an opportunity tointegrate lightweight parts with high-strength metallic panels whileavoiding the corrosion that generally occurs upon extended contactbetween the metallic panels. The connector is shaped to include channelportions having an activatable adhesive material located within thechannel portions. Edge portions of adjacent panels can be located withinthe channels so that a connection is maintained between adjacent panelswithout direct contact between the panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a connector and panels in accordancewith the present teachings.

FIG. 2 is a cross-sectional view of two connectors and associated panelsin accordance with the present teachings.

FIG. 3 is a cross-sectional view of a connector and panels in accordancewith the present teachings.

FIG. 4 is a cross-sectional view of a connector and panels in accordancewith the present teachings.

DETAILED DESCRIPTION

This application is related to and claims the benefit of the filing dateof U.S. Provisional Application Ser. No. 61/726,163 filed Nov. 14, 2012,the contents of this application being hereby incorporated by referencefor all purposes.

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the teachings, its principles,and its practical application. Those skilled in the art may adapt andapply the teachings in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present teachings as set forth are not intended as beingexhaustive or limiting of the teachings. The scope of the teachingsshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

The connector system (e.g., joint system, panel structures) of thepresent teachings provides a connector (e.g., a profile or post)including a channel portion and an activatable adhesive located in thechannel. One or more panels (e.g., structural members) may be locatedinto the channel portion and in contact with the activatable adhesive.The connector system may be utilized to form a hollow container.

The profile (e.g., channel portion) may include one or more surfaces forreceiving the activatable adhesive, which may be an adhesive sealant, anexpandable material, or any combination thereof. The channel may beformed so that it includes an opening for receiving a structural member,which may be a panel. The profile's surfaces may include a pair ofspaced apart opposing flanges (e.g., first and second walls) which maybe arranged substantially parallel to one another. The profile'ssurfaces may include a third wall intermediate the first and second wallthat may be arranged substantially perpendicular to the first and secondwalls. The surfaces of the profile may be substantially planar surfaces.The surfaces may include features that result in a variable topographyalong the surfaces of the profile.

An activatable material, which may be an adhesive material, a sealantmaterial, an expandable material, or any combination thereof, may belocated onto one or more of the profile's surfaces. The same activatablematerial may be located onto each surface. A different activatablematerial may be located onto each surface. The first and second wallsmay receive one activatable material, while the third wall receives anactivatable material that is dissimilar to that located onto the firstand second walls. One or more walls may receive an adhesive materialwhile one or more adjacent walls may receive an expandable material. Theadhesive material may or may not expand upon activation. The expandablematerial may or may not adhere upon activation.

The profile may be formed as a one-piece unitary member, such that eachmember forms two channel portions, each for receiving a structuralmember and/or acting to connect two or more structural members.Alternatively, the profile may be formed of two or more pieces that arearranged relative to one another to form the necessary channel portions.The two or more pieces may thus be connected to one another by means ofan adhesive, which may be the same adhesive located onto the profile'ssurfaces or may be a different adhesive. The two or more pieces may beconnected to one another via a mechanical fastener. The profiles may beformed to connect two or more structural members, which may be panelmembers.

The structural members may be metallic members. The first member andsecond member are generally dissimilar metallic members. One of thefirst or second member may be composed of aluminum, extruded aluminum,aluminum foam, magnesium, magnesium alloys, molded magnesium alloys,titanium, titanium alloys, molded titanium alloys, nickel, copper,transition metals, polyurethanes, polyurethane composites, or anycombination thereof. One of the first or second member may be a steelmember.

The connector includes a carrier which may be formed of a polymericmaterial. The carrier, including the walls and the ribs of the carriermay be integrally molded (e.g., injection molded) or formed of a singlematerial that is different from the material of one or more of the firstmember, the second member, or the expandable adhesive material. Suitablematerials can include for example, and without limitation, a polymericmaterial such as nylon, polyamide, polyester, polypropylene,polyethylene, molding compound or the like, which may be filled orunfilled (e.g., filled with glass or kevlar reinforcement fibers).

One function of the connector, in addition to separating the first andsecond members, is to provide a structural member that carries thestructural adhesive material. The carrier may thus be contacted with oneor more structural adhesive materials which may be expandable materials.Thus, the carrier may include one or more outward facing surfaces ontowhich a layer of the expandable material is placed. The expandablematerial may be applied to the surface of the carrier (prior toexpansion) at such locations. Optionally, the direction of expansion maybe controlled by one or more extensions formed on the carrier, such asthose disclosed in U.S. Pat. No. 6,941,719. The expandable material maybe formed onto one or more corners of the carrier. One or more spacesformed in between the first member and second member may be ofinsufficient size to fit the expandable material in its unexpandedstate. The carrier may thus be formed to guide the expandable materialfrom its location on the corner portions of the carrier into the smallclearances formed adjacent the corner portions between the first memberand second member. The inclusion of the expandable adhesive into thesesmall clearances provide improved strength of adhesion between the firstand second members by virtue of the thin bondline formed by the adhesiveexpanding to these thin openings. The carrier may be substantiallyrectangular in shape and may thus include a top surface, a bottomsurface, two side surfaces, a front surface and a back surface. Each ofthese surfaces may be formed of one or more openings, rib structures,solid surfaces, or combinations thereof. Thus, one or more areasdirectly adjacent (e.g., in direct planar contact with) the top surface,the bottom surface or the two side surfaces may be free of anyexpandable material in its unexpanded state. Upon activation of theexpandable material, the expandable material may foam and extend intothe areas directly adjacent one or more of the top surface, the bottomsurface, or the two side surfaces.

One or more of the adhesive and/or the expandable material may be anepoxy based material such as those disclosed in U.S. Pat. Nos.5,884,960; 6,348,513; 6,368,438; 6,811,864; 7,125,461; 7,249,415; andU.S. Patent Publication Nos. 2004/0076831, and 2008/0029200 herebyincorporated by reference for all purposes. The expandable materialand/or adhesive material may be generally shaped in a rectangular orblock configuration, but may also be shaped as needed or desireddepending upon the configuration of the carrier. As an example, theexpandable and/or adhesive material may be polygonal in shape and formedalong the corner portions of the carrier. More specifically, theexpandable material and/or adhesive material may be pentagonal in shapeand aligned along one or more corners of the carrier. Of course, it iscontemplated that the material may be applied to carrier as a singlepiece (e.g., strip) or multiple pieces (e.g., strips). Upon expansionthe expandable material and/or adhesive material may expand verticallyinitially until contacting any barrier at which point the expandablematerial may begin to expand in a horizontal direction, thus contactingone or more of the top surface, bottom surface or two side surfaces ofthe carrier. The expandable material and/or adhesive material may beable to expand into any gap with a width larger than about 0.5 mm. Theexpandable material and/or adhesive material may be able to expand intoany gap with a width larger than about 1 mm.

The expandable material and/or adhesive material may be a resinousgenerally dry to the touch or tacky and may be shaped in any form ofdesired pattern, placement, or thickness, but is preferably ofsubstantially uniform thickness. Though other heat-activated materialsare possible for the expandable material, a preferred heat activatedmaterial is an expandable polymer or plastic, and preferably one that isfoamable. The expandable material may be a relatively high expansionfoam having a polymeric formulation that includes one or more of anepoxy resin, an acetate (e.g. ethylene vinyl acetate), a thermoplasticpolyether, an acrylate and/or a methacrylate (e.g., a copolymer of butylacrylate and methyl acrylate), an epoxy/elastomer adduct, and one ormore fillers (e.g., a clay filler, and/or a nanoparticle-containingfiller). Preferred thermally expandable materials are disclosed in U.S.Pat. Nos. 7,313,865; 7,125,461; and 7,199,165 incorporated by referenceherein for all purposes. For example, and without limitation, theexpandable material may also be an EVA/rubber based material, includingan ethylene copolymer or terpolymer that may possess an alpha-olefin. Asa copolymer or terpolymer, the polymer is composed of two or threedifferent monomers, i.e., small molecules with high chemical reactivitythat are capable of linking up with similar molecules. Suitableexpandable materials include those available from L&L Products, Inc.under the designations L7220, L2821, L1066, L205, L2010, L2105, L2108A,L2806, L2811, L4200, L4141, L4161, L4315, L5510, L5520, L5540, L5600,L5601, L7102, and L7104.

The expandable material and/or adhesive material can be formed of othermaterials provided that the material selected is heat-activated orotherwise activated by an ambient condition (e.g. moisture, pressure,time or the like) and cures under appropriate conditions for theselected application, One such material is the epoxy based resindisclosed in U.S. Pat. No. 6,131,897, the teachings of which areincorporated herein by reference. Some other possible materials include,but are not limited to, polyolefin materials, copolymers and terpolymerswith at least one monomer type an alpha-olefin, phenol/formaldehydematerials, phenoxy materials, and polyurethane materials with high glasstransition temperatures. Additional materials may also be used such asthose disclosed in U.S. Pat. Nos. 5,766,719; 5,755,486; 5,575,526; and5,932,680, incorporated by reference herein for all purposes.

In applications where the expandable material and/or adhesive materialis a heat activated material, an important consideration involved withthe selection and formulation of the material is the temperature atwhich a material cures and, if expandable, the temperature of expansion.Typically, the material becomes reactive (cures, expands or both) athigher processing temperatures, such as those encountered in anautomobile assembly plant, when the material is processed along with theautomobile structures at elevated temperatures or at higher appliedenergy levels, e.g., during coating (e.g., e-coat, paint or clearcoat)curing steps. While temperatures encountered in an automobile assemblyoperation may be in the range of about 148.89° C. to 204.44° C. (about300° F. to 400° F.) for body shop applications (e.g., e-coat) and, forpaint shop applications, are commonly about 93.33° C. (about 200° F.) orslightly higher (e.g., 120° C.-150° C.).

The components of the connector may be arranged in a variety ofconfigurations. As shown for example in FIG. 1 , the connector 10includes a channel portion 12, the channel portions including anadhesive 14 and an expandable material 16 located therein. A connectingportion 18 of a panel structure 20 may be located within the channelportion 12 so that the connecting portion contacts the adhesive 14 alonga first surface 22 and second surface 24 of the panel and contacts theexpandable material 16 along a side edge 26 of the panel.

Alternatively, and as shown for example at FIG. 2 , the connector 10,includes a channel portion 12 having only an adhesive 14 located withinthe channel. Each of the first surface 22, second surface 24, and sideedge 26 of the panel structure 20 contacts the adhesive 14.

The connector may also be formed of a two-piece member as shown forexample at FIG. 3 . The connector may include a first portion 28 and asecond portion 30, such that the first portion receives the secondportion and forms an interface 32 between the first and second portion.The connection of the first portion 28 and second portion 30 forms achannel portion 12 for receiving a connecting portion 18 of the panelstructure 20. As such, the adhesive 14 is located in the interface 32between the first portion 28 and second portion 30 of the connector. Theadhesive 14 is also located within the channel portion 12 so that theadhesive contacts the first surface 22, second surface 24, and side edge26 of the panel structure 20.

The connectors may also be used in series such that adjacent connectorsmay have differing arrangements. As shown for example at FIG. 4 , afirst panel structure 20 a, second panel structure 20 b and third panelstructure 20 c may be aligned and connected via a first connector 10 aand a second connector 10 b. The first connector 10 a may be arranged asa one-piece connector and may include a channel portion 12 havingadhesive 14 located therein. The adhesive 14 may be located within thechannel 12 so that it contacts the first surface 22, second surface 24,and side edge 26 of the panel structure 20 a, 20 b. An adjacentconnector 10 b may be arranged as a one-piece connector and may alsoform channel portions 12 having adhesive 14 located therein. Theadhesive 14 contacts the first surface 22 and second surface 24 of thepanel structure 20, and an expandable material 16 is also located withinthe channel portion 12, but contacts the side edge 26 of the panelstructure 20 b, 20 c.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least 2 units between any lower value and anyhigher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to 70, it is intendedthat values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. areexpressly enumerated in this specification. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner. As can beseen, the teaching of amounts expressed as “parts by weight” herein alsocontemplates the same ranges expressed in terms of percent by weight.Thus, an expression in the Detailed Description of the Invention of arange in terms of at “‘x’ parts by weight of the resulting polymericblend composition” also contemplates a teaching of ranges of samerecited amount of “x” in percent by weight of the resulting polymericblend composition.”

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of theelements, ingredients, components or steps. By use of the term “may”herein, it is intended that any described attributes that “may” beincluded are optional.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

The invention claimed is:
 1. A panel structure for a containercomprising: at least two elongated panels including a panel adhesivelocated thereon; a panel connector is a two-piece member including afirst portion and a second portion such that the first portion receivesthe second portion and forms an interface located between the at leasttwo elongated panels for securing the at least two elongated panels toone another, the panel connector having an elongated profile thatdefines a pair of channels into which the at least two elongated panelsare placed and in which an adhesive sealant material resides foradhesively bonding and sealing the at least two elongated panels and thepanel connector to one another; wherein the elongated profile in crosssection has a configuration that includes a central portion that istubular and includes spaced apart opposing flanges defining twochannels; wherein the adhesive sealant is located in between theelongated profile and the at least two elongated panels so the elongatedprofile is free from direct contact with any portion of the at least twoelongated panels; wherein the panel adhesive has a Tg that differs froma Tg of the adhesive sealant so that the adhesive sealant is debondableby the application of heat so that the joint allows for removal andreplacement of one or more of the at least two elongated panels withoutdebonding the elongated panels and the panel adhesive.
 2. The panelstructure of claim 1, wherein the adhesive sealant is expandable.
 3. Thepanel structure of claim 2, wherein the adhesive sealant fills gapsalong a terminal edge of each structural member.
 4. The panel structureof claim 1, wherein panel connector is adapted for allowing removal andreplacement of each of the at least two elongated panels.
 5. The panelstructure of claim 1, wherein the panel connector is extruded.
 6. Thepanel structure of claim 1, wherein the panel connector includes analuminum material, a steel material, or any combination thereof.
 7. Thepanel structure of claim 1, wherein the panel connector includes aglass-reinforced polymeric material.
 8. The panel structure of claim 1,wherein the adhesive sealant cures in the absence of any curing agent.9. A panel structure for a container comprising: at least two elongatedpanels including a panel adhesive located thereon; a panel connectorcomprised of a glass-reinforced polymeric material is a two-piece memberincluding a first portion and a second portion such that the firstportion receives the second portion and forms an interface locatedbetween the at least two elongated panels for securing the at least twoelongated panels to one another, the panel connector having an elongatedprofile that defines a pair of channels into which the at least twoelongated panels are placed and in which an adhesive sealant materialresides for adhesively bonding and sealing the at least two elongatedpanels and the panel connector to one another; wherein the adhesivesealant is expandable; wherein the elongated profile in cross sectionhas a configuration that includes a central portion that is tubular andincludes spaced apart opposing flanges defining two channels; whereinthe adhesive sealant is located in between the elongated profile and theat least two elongated panels so the elongated profile is free fromdirect contact with any portion of the at least two elongated panels;and wherein the panel adhesive has a Tg that differs from a Tg of theadhesive sealant so that the adhesive sealant is debondable by theapplication of heat so that the joint allows for removal and replacementof one or more of the at least two elongated panels without debondingthe elongated panels and the panel adhesive.